U.S. patent number 10,486,382 [Application Number 15/243,944] was granted by the patent office on 2019-11-26 for coil spring compactor.
This patent grant is currently assigned to Olaf Industries, Inc.. The grantee listed for this patent is Olaf Industries, Inc.. Invention is credited to Clint Deraas, Eugene Luoma.
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United States Patent |
10,486,382 |
Deraas , et al. |
November 26, 2019 |
Coil spring compactor
Abstract
A compactor that compresses the springs in at least two,
preferably three different directions. One compression is achieved
through actuation of a crush chamber door. At least two of the
three directions of compression are perpendicular to an axis
through the springs. After the final compression is performed, the
compressed springs are discharged from the crush chamber in a
direction parallel to the direction of the final compression.
Inventors: |
Deraas; Clint (Duluth, MN),
Luoma; Eugene (Duluth, MN) |
Applicant: |
Name |
City |
State |
Country |
Type |
Olaf Industries, Inc. |
Duluth |
MN |
US |
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Assignee: |
Olaf Industries, Inc. (Duluth,
MN)
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Family
ID: |
42728850 |
Appl.
No.: |
15/243,944 |
Filed: |
August 22, 2016 |
Prior Publication Data
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Document
Identifier |
Publication Date |
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US 20160354988 A1 |
Dec 8, 2016 |
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Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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14306129 |
Jun 16, 2014 |
9421727 |
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12724320 |
Mar 15, 2010 |
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61160252 |
Mar 13, 2009 |
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61266143 |
Dec 2, 2009 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B30B
7/04 (20130101); B30B 9/327 (20130101); B30B
13/00 (20130101); B30B 9/3078 (20130101); B30B
15/32 (20130101); B30B 9/00 (20130101) |
Current International
Class: |
B30B
13/00 (20060101); B30B 9/32 (20060101); B30B
7/04 (20060101); B30B 9/00 (20060101); B30B
9/30 (20060101); B30B 15/32 (20060101) |
Field of
Search: |
;100/35,42,232 |
References Cited
[Referenced By]
U.S. Patent Documents
Other References
United States Patent and Trademark Office, Notice of Allowance
dated Apr. 20, 2016 in U.S. Appl. No. 14/306,129, 9 pages. cited by
applicant .
United States Patent and Trademark Office, Office Action dated Sep.
22, 2015 in U.S. Appl. No. 14/306,129, 9 pages. cited by applicant
.
United States Patent and Trademark Office, Office Action dated Mar.
27, 2015 in U.S. Appl. No. 14/306,129, 11 pages. cited by applicant
.
United States Patent and Trademark Office, Office Action dated Mar.
14, 2014 in U.S. Appl. No. 12/724,320, 11 pages. cited by applicant
.
United States Patent and Trademark Office, Final Office Action
dated Apr. 9, 2013 in U.S. Appl. No. 12/724,320, 10 pages. cited by
applicant .
United States Patent and Trademark Office, Office Action dated Aug.
20, 2012 in U.S. Appl. No. 12/724,320, 10 pages. cited by applicant
.
WIPO, International Search Report dated Jul. 6, 2010 in
International Patent Application No. PCT/US10/27348, 3 pages. cited
by applicant .
http://www.mattressrecycling.biz/xpp_art.shtml, "Spring
Compactor--Patent Pending," Table of Contents of site containing
individual pages of provisional patent application by Cecil Ray
Taylor, Independence, Missouri; see all web pages linked on this
page; accessed Oct. 6, 2010, 2 pages. cited by applicant.
|
Primary Examiner: Nguyen; Jimmy T
Attorney, Agent or Firm: Inskeep IP Group, Inc.
Parent Case Text
RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser.
No. 14/306,129 filed Jun. 16, 2014 (issuing as U.S. Pat. No.
9,421,727 on Aug. 23, 2016) entitled Coil Spring Compactor, which
is a divisional of and claims priority to abandoned U.S. patent
application Ser. No. 12/724,320 filed Mar. 15, 2010 entitled Coil
Spring Compactor, and which also claims priority to U.S.
Provisional Application Ser. No. 61/266,143 filed Dec. 2, 2009,
entitled Coil Spring Compactor and U.S. Provisional Application
Ser. No. 61/160,252, filed Mar. 13, 2009, entitled Coil Spring
Compactor, the contents of all of which are incorporated in their
entireties herein.
Claims
What is claimed is:
1. A method for compacting springs from mattresses and/or box
springs comprising: compressing at least one spring in a first
direction parallel to an axis formed through the at least one
spring; compressing the at least one spring in a second direction
perpendicular to an axis formed through the at least one spring;
compressing the at least one spring in a third direction
perpendicular to an axis formed through the at least one spring;
and discharging the at least one spring from a crush chamber in a
direction parallel to the third direction.
2. The method of claim 1 wherein compressing at least one spring in
the first direction comprises placing the at least one spring
horizontally upon a crush chamber door.
3. The method of claim 1 wherein compressing at least one spring in
the first direction comprises closing a chamber door to form a
portion of one side of the crush chamber.
4. The method of claim 1 wherein compressing at least one spring in
the first direction comprises transposing a crush chamber door from
an open, horizontal position to a closed, vertical position.
5. The method of claim 1 wherein compressing the at least one
spring in the second direction comprises reducing an interior
vertical dimension of the crush chamber.
6. The method of claim 1 wherein compressing the at least one
spring in the second direction comprises maintaining a compression
surface horizontally level during the compressing.
7. The method of claim 1 wherein compressing the at least one
spring in the second direction comprises compressing the at least
one spring in a second direction while maintaining the compression
of the at least one spring in the first direction.
8. The method of claim 1 wherein compressing the at least one
spring in the third direction comprises compressing the at least
one spring in a third direction while maintaining the compression
of the at least one spring in the first direction and the second
direction.
9. A method for preparing springs from a mattress and/or box spring
for processing by a foundry comprising: placing a metal spring on a
horizontally oriented door of a crush chamber; compressing the
metal spring in a first direction parallel with an axis through the
metal spring by advancing the door of the crush chamber from a
horizontal position to a vertical, closed position; compressing the
metal spring in a second direction; compressing the metal spring in
a third direction; and discharging the metal spring from the crush
chamber in a direction parallel with the third direction.
10. The method of claim 9 wherein compressing the metal spring in
the second direction comprises compressing the metal spring in a
direction perpendicular to an axis through the metal spring.
11. The method of claim 9 wherein compressing the metal spring in
the third direction comprises compressing the metal spring in a
direction perpendicular to an axis through the metal spring.
12. The method of claim 9 wherein discharging the metal spring from
the crush chamber in the direction parallel with the third
direction comprises discharging a mass of metal having a density of
60-100 pounds per cubic foot.
13. A method for compacting springs from mattresses and/or box
springs comprising: loading at least one spring into a crush
chamber; compressing the at least one spring in a first direction
parallel to an axis formed through the at least one spring;
compressing the at least one spring in a second direction
perpendicular to an axis formed through the at least one spring;
compressing the at least one spring in a third direction
perpendicular to an axis formed through the at least one spring;
and discharging the at least one spring from the crush chamber in a
direction parallel to the third direction.
14. The method of claim 13 wherein loading at least one spring into
the crush chamber comprises placing the at least one spring
horizontally upon a chamber door.
15. The method of claim 13 wherein loading at least one spring into
the crush chamber comprises closing the chamber door to form a
portion of one side of the crush chamber.
16. The method of claim 13 wherein compressing the at least one
spring in the second direction comprises reducing an interior
vertical dimension of the crush chamber.
17. The method of claim 13 wherein compressing the at least one
spring in the second direction comprises maintaining a compression
surface horizontally level during the compressing.
18. The method of claim 13 wherein compressing the at least one
spring in the third direction comprises compressing the at least
one spring in the third direction while maintaining the compression
of the at least one spring in the first direction and the second
direction.
19. The method of claim 13 wherein discharging the at least one
spring from the crush chamber comprises discharging a mass of metal
having a density of 60-100 pounds per cubic foot.
Description
FIELD OF THE INVENTION
This application relates to an apparatus and method for compacting
springs and, more particularly, to an apparatus and method for
compacting and preparing the metal components of mattresses for
recycling.
BACKGROUND OF THE INVENTION
Modern mattresses are made from various combinations of materials
including: synthetic and natural fabrics, feathers, foam, plastics,
wood, and arrangements of metal springs. The disposal and recycling
of mattresses is a complicated process that involves both
separating the various mattress materials from each other and also
preparing each of the resulting materials in a bundle that meets
the specific acceptance requirements of the various recyclers. For
example, the metal springs of mattresses form an interconnected
array of metal that occupies a relatively large area at a low
density. Metal foundries, however, accept metal in relatively small
volume, high-density units, for example one cubic foot units or
blocks of approximately 60 to 100 pounds. Efficient systems and
methods for compacting resilient springs to such densities have
thus far not been developed in the field. Accordingly, there exists
a need to efficiently process low-density mattress springs into
high-density units accepted by typical foundries.
OBJECTS AND SUMMARY OF THE INVENTION
The present invention addresses this need by providing systems and
methods for efficiently compacting the springs of mattresses and
box springs. The present invention compresses the springs in at
least two, preferably three different directions. One compression
is achieved through actuation of a crush chamber door. At least two
of the three directions of compression being perpendicular to an
axis through the springs. After the final compression is performed,
the compressed springs are discharged from the crush chamber in a
direction parallel to the direction of the final compression.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other aspects, features and advantages of which
embodiments of the invention are capable of will be apparent and
elucidated from the following description of embodiments of the
present invention, reference being made to the accompanying
drawings, in which
FIG. 1 is a front elevation view of a spring compactor according to
certain embodiments of the present invention.
FIGS. 2A and 2B are side elevation views of a spring compactor
according to certain embodiments of the present invention.
FIG. 3 is a front elevation view of a spring compactor according to
certain embodiments of the present invention.
FIGS. 4A and 4B are side elevation views of a spring compactor
according to certain embodiments of the present invention.
FIG. 5 is a sectional view taken along lines A-A of FIG. 3 of a
spring compactor according to certain embodiments of the present
invention.
FIG. 6 is a side elevation view of a spring compactor according to
certain embodiments of the present invention.
FIG. 7 is a sectional view taken along lines B-B of FIG. 1 of a
spring compactor according to certain embodiments of the present
invention.
FIG. 8 is a flow diagram of a method for preparing springs from a
mattress and/or box spring for processing by a foundry according to
certain embodiments of the present invention.
DESCRIPTION OF EMBODIMENTS
Specific embodiments of the invention will now be described with
reference to the accompanying drawings. This invention may,
however, be embodied in many different forms and should not be
construed as limited to the embodiments set forth herein; rather,
these embodiments are provided so that this disclosure will be
thorough and complete, and will fully convey the scope of the
invention to those skilled in the art. The terminology used in the
detailed description of the embodiments illustrated in the
accompanying drawings is not intended to be limiting of the
invention. In the drawings, like numbers refer to like
elements.
Unless otherwise defined, all terms (including technical and
scientific terms) used herein have the same meaning as commonly
understood by one of ordinary skill in the art to which this
invention belongs. It will be further understood that terms, such
as those defined in commonly used dictionaries, should be
interpreted as having a meaning that is consistent with their
meaning in the context of the relevant art and will not be
interpreted in an idealized or overly formal sense unless expressly
so defined herein.
The coil spring compactor of the present invention is operable to
simultaneously compact a plurality of springs from mattresses
and/or box springs into a compressed unit that is of a density
accepted by commercial metal foundries. For example, in a preferred
embodiment, the compactor of the present invention compacts four
mattress springs into a 12 inch wide by 6 inch high by 18 inch long
mass of approximately 60 to 100 pounds, preferably 75 pounds.
As shown in FIGS. 1-7, in certain embodiments of the present
invention, a coil spring compactor 10 employs a six sided magazine
or crush chamber 12. The crush chamber is approximately rectangular
having a height and width dimensioned so as to accept at least the
springs from a king size mattress or box springs. The internal
dimensions of the crush chamber 12 may, for example, be 78 inches
high by 88 inches wide by 12 inches deep.
As shown in FIGS. 2A, 2B, 4A, 4B, and 5, the upper most horizontal
surface of the crush chamber 12 employs one or more vertical
compression plates 14. The vertical compression plates 14 are
attached to or otherwise associated with one or more vertical
compression hydraulic cylinders 15 or other similar means to
vertically transpose the vertical compression plate through crush
chamber 12. In embodiments employing more than one vertical
compression hydraulic cylinders 15, it will be necessary to
maintain the vertical compression plate 14 level relative to the
different compression hydraulic cylinders 15. In one embodiment,
the vertical compression plate 14 is maintained level by plumbing
the hydraulic system from one of the vertical compression hydraulic
cylinders 15 into the hydraulic system of the other vertical
compression hydraulic cylinder 15. Alternatively, the vertical
compression plate 14 and the vertical compression hydraulic
cylinders 15 may incorporate either a mechanical or electrical
level control system. For example, the coil spring compactor 10 may
employ a programmable electronic leveling system combined with
fluid control valves to provide constant vertical compression plate
14 leveling. The lower most horizontal surface, the surface
opposite the vertical compression plates 14, employs a vertical
compression counter surface 16, shown in FIGS. 5-7.
As shown in FIGS. 1-5 and 7, a chamber door 18 forms at least a
portion of one of the large vertical sides of the crush chamber 12
when the chamber door 18 is in a closed state, shown in FIGS. 1,
2A, 3, 4B, and 7. The chamber door 18 employs a hinge 20 on a lower
side 22 of the chamber door 18, see FIG. 5. When the chamber door
18 is opened, shown in FIGS. 2B, 4A, and 5, the upper side 24 of
the chamber door 18 is transposed in an arc-like form 19 away from
the crush chamber 12 and downward. When fully opened, chamber door
18 forms an approximately horizontal surface extending
approximately perpendicular from the crush chamber 12. In the open
position, the camber door 18 functions as a spring loading
platform. In certain embodiments, the arc-like form 19 reflects the
outline of chamber door side walls (not shown) that are employed on
either side of the chamber door 12. The chamber door side walls are
attached to the crush chamber 12 such that the side walls function
to guide the springs loaded onto the open chamber door 18 into the
crush chamber 12 when the chamber door 18 is transitioning from the
open state to the closed state.
The chamber door 18 may be actuated, or opened and closed, by
employing one or more chamber door hydraulic cylinders 26. The
chamber door hydraulic cylinders 26 may be anchored to the exterior
sides of the crush chamber 12 and chamber door 18, as shown in
FIGS. 1-2B, or may be anchored on a frame residing on a floor or
other work surface and to central locations on an exterior surface
of the chamber door 18, as shown in FIGS. 3-5. The chamber door 18
may, for example, be 61 inches high by 88 inches wide. The second
large vertical side of the crush chamber 12 employs a chamber door
counter surface 27, shown in FIGS. 2A, 2B, 4A, 4B, 5 and 7.
The remaining two sides of the crush chamber 12 are the two small,
vertical sides located opposite each other and form the first end
surface 30 and the second end surface 32. As shown in FIG. 7, the
first and second end surfaces 30 and 32 extend downwards along the
sides of the crush chamber 12 to a discharge door 34 and a
horizontal compression plate 36, respectively. The horizontal
compression plate 36 is attached to or otherwise associated with a
horizontal compression hydraulic cylinder 38 which functions to
transpose the horizontal compression plate 36 horizontally through
a lower portion of the crush chamber 12. The discharge door 34,
located opposite the horizontal compression plate 36, counters the
horizontal movement of the horizontal compression plate 36. The
discharge door 34 is transposable so as to form an opening into a
lower portion of the crush chamber 12. The discharge door 34 may be
actuated by employing a discharge door hydraulic cylinder 35 or
other similar means of transposing. In certain embodiments of the
present invention, a discharge hydraulic cylinder 35 is employed so
as to transpose the discharge door 34 horizontally away from the
crush chamber 12, as shown in FIG. 1. In certain other embodiments,
the discharge door hydraulic cylinder 35 is configured so as to
transpose the discharge door 34 vertically along an exterior of the
first end surface 30, shown in FIGS. 3 and 6.
It will be appreciated by those of skill in the art that interior
surfaces of the crush chamber 12 will be subjected to significant
resistance and subsequent wear during operation. In order to
improve the longevity of the interior surfaces, in certain
embodiments of the present invention, the interior surfaces of the
crush chamber 12 employ, for example, abrasive resistant steel
plates. In certain other embodiments, the interior surfaces of the
crush chamber 12 are designed such that the individual components
may be rotated, reversed, or interchanged with other interior
surface components such that specific portions of the surfaces
subject to disproportional wear may be moved to areas of less wear
are without altering the operability of the coil spring compactor
10. For example, the wear plates forming the first end surface 30
and the second end surface 32 may be substantially identical and
therefore interchangeable. If, for example, the first end surface
30 is worn more extensively than the second end surface 32, the two
surfaces can be interchanged so as to maximize the use of both
surfaces. Furthermore, the individual surfaces may be designed such
that the surface, for example the chamber door counter surface 26,
can be rotated 180 degrees and remounted with the same surface
forming the interior surface or may be reversed such that the
interior and exterior surfaces are reversed. In order to facilitate
these features the interior surfaces of the crush chamber 12 may
have symmetrical shapes, such as rectangular shapes, and
symmetrical mounting means, for example equally spaced threaded
holes.
With reference to FIG. 8, in a step 102 of a method for preparing
springs from a mattress and/or box spring from processing by a
foundry according to the present invention, the springs from
dismantled mattresses are separated from non-spring elements of the
mattress or box spring. In a step 104, the springs 5 are then
placed horizontally onto an elevated planar surface formed by an
open chamber door 18, shown in FIGS. 2A, 2B, 4A, 4B, and 5. In a
step 106, the chamber door 18 is then closed to form at least a
portion of one side of the crush chamber 12. Closing the chamber
door 18 positions the mattress springs 5 approximately vertically
upon their long sides within the crush chamber 12, shown in FIG.
4B. Depending on the number of springs loaded on to the open
chamber door 18, closing of the chamber door 18, provides the first
compression of the springs in a direction parallel to an axis
formed through the springs.
In a step 108, a second compression of the springs initiates with
displacement of the vertical compression plates 14 in a downward
direction by the vertical compression hydraulic cylinders 15. A
downward displacement of the vertical compression plates 14 results
in a decrease in the height of the crush chamber 12 and a first
compression of the springs in a direction approximately
perpendicular to an axis formed through the springs. Upon
displacement of the vertical compression plates 14 to a desired
height above the vertical compression counter surface 16, for
example a height of 6 inches above the vertical compression counter
surface 16, vertical compression ceases.
While maintaining the vertical compression plates 14 at the desired
height above the vertical compression counter surface 16, in a step
110, the horizontal compression plate 36 is transposed horizontally
through the bottom portion of the crush chamber 12 so as to
compress the springs in a third direction. It will be understood
that the third compression compresses the springs in a direction
approximately perpendicular to an axis formed through the springs
and in a direction approximately perpendicular to the direction of
the second compression. Horizontal compression ceases once a
desired hydraulic pressure in the horizontal compression hydraulic
cylinder 38 is achieved.
In a step 112, the compressed mattress springs are then discharged
from the crush chamber 12 by retracting, lifting, or otherwise
displacing of the discharge door 34 so as to form an opening at one
side of the lower crush chamber 12. The compressed mattress springs
are discharged from the crush chamber 12 by additional horizontal
displacement of the horizontal compression plate 36 towards the
opening formed by the now retracted discharge door 34. The
compressed springs can be discharged from the crush chamber 12 on
to a cart, conveyor belt, truck or other means for facilitating the
transportation of the compressed springs to a foundry.
In certain embodiments of the present invention, the compressed
mattress springs may be bundled or otherwise confined such that the
compressed springs better maintain their compressed state and/or to
facilitate handling and transport of the compressed springs.
In certain embodiments of the present invention, compression of the
mattress springs is facilitated through hydraulic displacement of
certain interior surfaces of the crush chamber 12. In a preferred
embodiment, the hydraulic displacement is achieved by employing a
motor 40, for example, an electric motor of ten horsepower.
However, it is noted that other suitable manners of achieving
displacement of the surfaces of the crush chamber 12 and other
suitable means for powering such displacement are well known in the
art and may also be employed to achieve similar results.
In certain other embodiments of the present invention, the spring
compactor 10 may be operated manually through the use of valve
controls 42, shown in FIG. 3. Alternatively, operation may be
automated such that after loading the springs on to the open
chamber door 18, an operator need only actuate a button of lever to
begin an automated compression cycle that results in the discharge
of a mass of compressed metal springs of a density accepted by
metal foundries.
Although the invention has been described in terms of particular
embodiments and applications, one of ordinary skill in the art, in
light of this teaching, can generate additional embodiments and
modifications without departing from the spirit of or exceeding the
scope of the claimed invention. Accordingly, it is to be understood
that the drawings and descriptions herein are proffered by way of
example to facilitate comprehension of the invention and should not
be construed to limit the scope thereof.
* * * * *
References